Machine and method for the production of rolls of impregnated web material

ABSTRACT

A peripheral winding machine for the production of rolls of wound web material is described, comprising a feed path for the web material (N), winding means ( 1, 3, 5 ) for winding said web material into rolls (L), and a zone for interruption of the web material along said feed path and upstream of said winding means, characterized in that it comprises applicator members ( 7 B) for applying a moistening product to said web material upstream from said winding means and downstream from said interruption zone.

DESCRIPTION

1. Technical Field

This invention relates to a method for the production of articles ofmanufacture comprising a web product soaked or moistened with a producthaving a liquid base. The invention also relates to a winding machinefor the production of rolls of soaked or moistened web material.

2. State of the Art

Products known as refreshing, disinfectant or detergent wipes comprisingsheets of paper material soaked in an aqueous solution of detergents,soaps and perfumed or other substances are currently manufactured.Normally these wipes are packed individually in sealed sachets. In somecases multiple packs are constructed, which contain a plurality ofmoistened wipes which can be removed from the pack individually.

OBJECT AND SUMMARY OF THE INVENTION

The object of the present invention is to provide a method and a devicefor the production of rolls of web material, for example but notexclusively of absorbent paper material, soaked or moistened withsubstances having a liquid base containing detergents, soaps, perfumedoils, disinfectants or other components.

Substantially the invention provides a method for the production ofrolls of wound web material in which the web material is fed along afeeding path to a winding zone where it is wound to form rolls, and inwhich characteristically a moistening product is applied to the webmaterial upstream from the winding zone. The roll is obtained in thisway by winding a web material which has already been impregnated withdetergent, deodorant, moisturizing, disinfectant or other products withwhich it is desired that the finished product be impregnated.

In practice the method comprises the stages of:

feeding the web material along a feed path to a winding zone in whichsaid web material is wound to form a first roll,

when winding of said first roll is complete, acting on said web materialin an interruption zone to produce an interruption in the web materialand produce a free end of web material,

beginning the winding of a second roll from said free end.

In accordance with the invention the method is characterized in that amoistening product is applied to the web material along said feed pathbetween the interruption zone and the winding zone.

By interruption zone is generally meant a zone along the web materialfeed path in which a force is applied to the latter which is intended tocause the breakage, tearing, cutting or in general interruption of theweb to conclude the winding of a first roll and produce the free leadingedge for formation of a subsequent roll. The interruption zone may bethat in which a blade acts on the web material in order to cut it.Alternatively, the interruption zone may be the zone in which a movingmember pinches the web material against a fixed member or another membermoving at an appropriately different speed. For example the interruptionzone may be a zone in which an oscillating or rotating member pressesthe web material against a feed and/or winding member, for example awinding roller or belt. Alternatively, it may be a zone in which atubular winding core or a winding mandrel presses the web materialagainst the feed or winding member, or against a fixed or movingsurface. In general, the interruption zone may coincide with the zone inwhich the free end of web material is formed; this occurs for examplewhen a cutting blade is used. However, more generally, the interruptionzone need not necessarily coincide with the zone where the free end isproduced, which latter may typically be downstream from the interruptionzone, at a point where tearing occurs as a result of overtensioning ofthe web material.

The method may advantageously be based on a winding system known as aperipheral or surface winding system, that is one in which the roll isformed in a winding cradle formed by winding members, such as typicallyrollers or belts or combinations thereof which contact the surface ofthe forming roll and keep it rotating.

In this embodiment it may be provided that the web material is passedround one of the winding members. In this case the moistening product isapplied, for example by spraying, to the web material while the lattertravels around the winding member. In this way the advantage is achievedthat the web material is supported by the surface of the winding memberwhile application takes place, and therefore prevents damage to thematerial. Also, the moistening product is applied in this wayimmediately upstream from the point where the web material is wound ontothe forming roll, and furthermore the web material is substantiallysupported by the winding member from the point at which the moisteningproduct is applied to the point where it is wound. This has the resultthat the weakening of the web material resulting from absorption of themoistening product does not result in any risk of breakage duringwinding. This aspect is particularly important in that the web materialtypically comprises paper known as “tissue”, non-woven fabric or othermaterial of little substance and mechanical strength which tends toweaken as a result of the absorption of liquids.

It may also be provided that the web material is passed around a cuttingroller and passes from this to one of the peripheral winding members. Inthis case the liquid may be applied to the web material while it ispassed around the cutting roller, advantageously downstream from thecutting zone. In this case too there is substantial support for themoistened web material until it is wound.

More generally it is particularly advantageous to provide that theliquid product be applied downstream of the changeover zone. Bychangeover zone is meant generically that zone in which the formation ofa new roll takes place at the start of each winding. The changeover zonemay be a zone in which the leading end of the web material istransferred to a winding mandrel or core. If winding takes place withouta core or without a mandrel the changeover is the stage in which theleading edge of the web material begins to wind or curl upon itself toform the initial core and thus the first turns of a new roll.

Means for interrupting the web material are normally provided along thepath traveled by the web material. The interruption of web materialmakes it possible to interrupt winding of the latter onto a now completeroll and begin the winding of a new roll.

When means for interruption of the web material are provided themoistening product is applied between the position at which the means ofinterruption act and the point at which winding of the roll takes place.The means of interruption may be any known means, for example a blade, apresser which breaks the web material by pinching it against a suitablesurface, for example even the surface of one of the winding members, avacuum system, or other means suitable for achieving interruption of theweb material through cutting, tearing, perforation and tearing,overtensioning or otherwise.

In accordance with a particularly advantageous embodiment of the methodaccording to the invention, a rolling plate is provided upstream fromthe winding zone along the feed path for the web material. The roll ofweb material is caused to roll along the rolling plate in the firststage of winding, towards the winding cradle where the roll is formed,winding being completed between the winding members. Means for sprayingthe moistening product are also provided at a terminal part of thewinding plate close to the winding cradle.

The roll is preferably wound without a central winding core, for exampleusing a winding system of the type described in U.S. Pat. No. 5,639,046or U.S. Pat. No. 5,538,199.

In accordance with the invention a winding machine is provided for theproduction of rolls of wound web material which comprises a feed pathfor the web material and winding means to wind the web material and formsaid rolls. Characteristically, applicator members for applying amoistening product to the web material while this is fed along said feedpath are provided upstream from the winding means.

The winding means are advantageously of the surface or peripheral type,that is they comprise peripheral winding means which form a windingcradle and which are in contact with the outer surface of the formingroll and which cause it to rotate by transmitting rotational movement byfriction. In this case the winding means comprise belts, winding rollersor combinations thereof, or equivalent peripheral winding members. Theapplicator members are advantageously and preferably associated with oneof the peripheral winding members along which the web material is passedprior to reaching the winding point.

Peripheral winding may take place on a central winding core which isthen retained within the finished product. In this case the winding coreis preferably constructed of a plastics or otherwise non-absorbentmaterial, in order to retain a uniform liquid content throughout thewound web material, including the first turns. Attentively the windingcore may comprise a removable mandrel which is subsequently removed fromthe wound roll. In accordance with the preferred embodiment however,winding takes place without a central core and without a mandrel, theleading end of the web material being wound onto itself.

In accordance with a particularly advantageous embodiment of the windingmachine according to the invention, a rolling plate is located along theweb material feed path upstream from the winding zone. The rolling plateends close to the winding cradle and extends partly around a peripheralwinding member around which the web material is fed, forming in effect atransfer channel for said web material with said winding member. In thisconfiguration the applicator members are advantageously associated withthe terminal end of the plate which lies closest to the winding cradle.

The applicator members may be constructed within said rolling plate, forexample in a terminal portion thereof of comb construction. In this caseprovision may be made for the applicator members to be constructed inthe form of nozzles formed by holes made in the plate. The plate itselfmay be a member formed from a plurality of assembled components, forexample a sheet and a terminal comb portion which together form a singlepiece.

Further possible advantageous features and embodiments of the windingmachine and the method according to the invention are indicated in theappended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood from the description and theappended drawing which shows a non-restrictive practical embodiment ofthe invention. In the drawing:

FIG. 1 shows the winding zone of a surface winding machine to which thisinvention is applied;

FIG. 2 shows a magnified cross-section along II—II in FIG. 4 of theterminal comb portion of the rolling plate for the roll during the firststage of the winding cycle,

FIG. 3 shows a cross-section similar to that in FIG. 2 along III—III inFIG. 5 in a different embodiment,

FIG. 4 shows a frontal view along IV—IV in FIG. 2,

FIG. 5 shows a frontal view along V—V in FIG. 3, and

FIG. 6 provides a diagrammatical view of a different embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION

FIG. 1 provides a lateral view of the winding zone of a winding machinein which this invention is implemented. The winding machine is of theperipheral type which winds without a central winding mandrel or core,of the type described in greater detail in U.S. Pat. No. 5,639,046, towhich reference may be made for greater detail. This description will berestricted to the items which are necessary for an understanding of thisinvention.

The winding machine has a winding cradle defined by three rollers 1, 3,5, in which roller 5 and possibly one of rollers 1 or 3 or both move toallow the roll or log L forming in the winding cradle to grow. Upstreamfrom the nip formed between the two winding rollers 1 and 3 there is anoscillating plate 7 supported by an oscillating arm 9 hinged about anaxis A which coincides with the axis of rotation of winding roller 3.

Oscillating plate 7 is formed from a sheet 7A and a terminal comb member7B, the teeth 7C of which (FIG. 2) are inserted into annular grooves 3Ain winding roller 3. The unit comprising oscillating arm 9, sheet 7A andcomb member 7B oscillates around axis A through the effect of a cam 11which rotates about an axis B and acts together with a contact member 13borne by arm 9. An elastic member such as a spring or other member, notshown, ensures that contact is maintained between the cam and thecontact member.

Web material N is fed around winding roller 1 and is delivered from aperforating unit, not shown. Web material N is then wound around roll orlog L which is kept in rotation by three rollers 1, 3, 5 in the windingcradle, until the desired quantity of web material has been wound ontolog L. Once winding is complete log L is removed from the winding cradlein a known manner, for example by acting on the peripheral speed of oneor both winding rollers 3 and 5, while oscillating plate 7 is caused tooscillate upwards (that is clockwise) so as to cause the web material tobe pinched between said plate and winding roller 1. This causes both theweb material to tear between the completed roll and the pinch point andthe free end so produced to wind upon itself to start the formation of anew roll.

The machine and the method of winding briefly described heretofore arealready known to those skilled in the art (see U.S. Pat. No. 5,639,046).

In accordance with the invention a liquid-based product whichimpregnates or moistens the material before forming roll or log L isapplied to web material N. With this object, in the embodimentillustrated, terminal comb member 7B of plate 7 has a series of nozzleswhich spray liquid product onto web material N as this passes by and isdelivered to winding roller 1 in the direction of forming roll or log L.

FIGS. 2 and 4 show a first possible configuration of these nozzles,which are indicated therein by 21. These are distributed in asubstantially uniform way along the entire longitudinal length ofterminal comb member 7B, that is along the transverse direction of webmaterial N. Nozzles 21 are connected to a duct 23 constructed in thebody of the terminal comb member, which feeds the liquid which has to besprayed to the individual nozzles 21. Duct 23 may be fed from outside atthe end of the comb member, and also at any intermediate points alongthe longitudinal length of duct 23 itself, in order to obtain anapproximately constant pressure and therefore a flow of liquid and anexit velocity from the individual nozzles which are sufficiently uniformalong the entire transverse extent of the web material.

Nozzles 21 are opportunely orientated towards the ends of teeth 7C ofcomb member 7B. In this way the jets of liquid generated by the nozzlesare orientated towards the nip formed between winding rollers 1 and 3and therefore intercept web material N in a position which is as closeas possible to the point in which the web material is detached from thesurface of winding roller 1 and winds onto log L. This reduces the risksof breakage of web material N through weakness caused by moistening.

FIGS. 3 and 5 show a modified embodiment in which the same referencenumbers indicate the same or equivalent parts as in FIGS. 2 and 4. Inthis case the nozzles are constructed in the teeth 7C of comb member 7Band therefore open out in a position which is even closer to the zonewhere log L is formed. Nozzles 21 are also fed through a duct 23constructed within the thickness of comb member 7B at the base of teeth7C.

A pair of nozzles which are orientated in a divergent manner areprovided in each tooth 7C. This increases the uniformity with which thesprayed liquid is distributed.

The possibility of also constructing nozzles 21 as separate members fromcomb member 7B, making space to house them in annular seats in windingroller 3, is not ruled out.

As an alternative it may be provided that the nozzles are housed withinwinding roller 1 or winding roller 3, in a fixed position and orientatedso as to intercept the web material in a zone suitably located close tothe winding point. In this case the nozzles can for example spraythrough previous zones of winding roller 1 or winding roller 3.

In any event, in the arrangement illustrated or the altemativesmentioned above the web material is moistened downstream from the pointwhere the “changeover” occurs, that is where the interrupted webmaterial begins the formation of a new roll. In the example illustratedthe changeover zone is substantially represented by the zone in whichthe free end of web material obtained by tearing begins to wind uponitself to form the initial core of a new roll. With this invention thischangeover, which constitutes a critical operation in the windingprocess, is caused to take place with material which is substantiallydry. The presence of moisture or liquid impregnating the material wouldmake the changeover difficult or would in some cases even render itimpossible, with the consequence that the winding process could not beperformed continuously. These difficulties may be caused not only by thereduced strength of the wetted material but also by the increase incentrifugal force produced by the increase in the specific gravity ofthe wetted material. Furthermore, the possible use of soaps or softenersin the applied liquid reduces the friction coefficient between the webmaterial and the members of the machine in contact with it at the timeof changeover. The consequent slippage may prejudice or createdifficulties for changeover.

In order to ensure that the changeover zone remains dry, provision mayalso be made for the presence of nozzles 30 located upstream fromoscillating plate 7. These nozzles generate a jet of dry air whichremoves any moisture originating in the zone where the web material issprayed from the changeover zone.

FIG. 6 shows an embodiment in which winding is performed on tubularwinding cores, for example of plastics material. The structure of thewinding zone is similar to that described in U.S. Pat. No. 4,487,377, towhich reference may be made for greater detail. The winding cradle isformed by three winding rollers 1, 3, 5. Winding roller 1 also has acutting channel which acts together with a blade 4 mounted on ablade-holding roller 6. Winding roller 1 therefore also constitutes acutting roller. In this way, once a roll or log L has been woundblade-holding roller 6 causes blade 4 to act together with the channelor counterblade in the cutting and winding roller 1 effects interruptionof the web material. A pneumatic or mechanical retaining systemassociated with roller 1 transfers the leading end of the cut materialto the new winding core A which is inserted by a pusher 8 into the nipbetween rollers 1 and 3. Downstream from the zone where cutting of theweb material takes place, that is from the nip between rollers 1 and 6,there is located a set of spray nozzles 101 which spray the liquidagainst the web material when the latter is supported on roller 1. Inthis configuration too there is the advantage that the web material issupported on a mechanical member (roller 1) when it is wetted, avoidingrisks of breakage.

Alternatively, and in a way which is in itself known, the web materialmay also be cut by means of a cutting roller which is separate fromwinding roller 1, and which may be located upstream of the latter in thedirection of advance of the web material. In this case means areprovided for transferring the free leading end of the web material fromthe roller on which cutting takes place to the winding roller. Anarrangement of this type is for example illustrated in U.S. Pat. No.4,962,897. Again in a configuration of this type the spray nozzles areadvantageously associated with the cutting roller or the subsequentwinding roller and spray the liquid downstream from the cutting zone.

A configuration with a cutting blade and a cutting roller may also beconstructed for winding without a central winding core.

It is to be understood that the drawing only illustrates an embodimentwhich has merely been provided as a practical demonstration of theinvention, and this invention may vary in form and arrangement withoutthereby going beyond the scope of the concept underlying the invention.

What is claimed is:
 1. Method for producing rolls of wound web material,comprising the stages of: feeding the web material along a feed path toa winding zone in which said web material is wound to form a first roll,when winding of said first roll is complete, acting on said web materialin an interruption zone to produce an interruption in the web materialand produce a free end of web material, beginning the winding of asecond roll from said free end, wherein a moistening product is appliedto the web material along said feed path between the interruption zoneand the winding zone to provide rolls of soaked or moistened webmaterial.
 2. Method according to claim 1, further comprising arranging awinding cradle defined by peripheral winding members in contact with aforming roll.
 3. Method according to claim 2, wherein said moisteningproduct is applied to the web material at one of said winding members towhich the web material is fed.
 4. Method according to claim 2 or 3,further comprising providing a rolling surface upstream from the windingzone along which the roll is caused to roll towards the winding cradle,and wherein means for spraying the moistening product are arranged at aterminal part of the rolling surface close to the winding cradle. 5.Method according to claim 2, wherein a changeover zone in which aleading free end of the web material begins the formation of a new rollis provided along said feed path, said moistening product being applieddownstream from said changeover zone in the direction of advance of theweb material along said path.
 6. Method according to claim 2, 3 or 5,wherein a device for interrupting the web material is provided alongsaid feed path upstream from the winding zone; and that said moisteningproduct is applied to the web material while the web material is intransit between the device for interrupting the web and the windingzone, wherein said device for interrupting the web acts together with awinding roller, said winding roller being one of said peripheral windingmembers.
 7. Method according to claim 1, wherein said web material iswound without a central winding core.
 8. Method according to claim 1,wherein a changeover zone in which a leading free end of the webmaterial begins the formation of a new roll is provided along said feedpath, said moistening product being applied downstream from saidchangeover zone in the direction of advance of the web material alongsaid path.
 9. Method according to claim 1, 2, 3, 5 or 8, wherein adevice for interrupting the web material is provided along said feedpath upstream from the winding zone; and that said moistening product isapplied to the web material while the web material is in transit betweenthe device for interrupting the web and the winding zone.
 10. Methodaccording to claim 9, wherein said device for interrupting the webcomprises a blade and a roller around which said web material is fed,said blade acting together with said roller, and in that said moisteningproduct is sprayed onto the web material while the web material ispassed around said roller.
 11. Method according to claim 8, wherein aninterruption device acts together with a winding roller, said windingroller being a peripheral winding member.
 12. Peripheral winding machinefor the production of rolls of wound web material comprising a feed pathfor a web material, winding means for winding said web material inrolls, and a zone for interruption of the web material along said feedpath and upstream from said winding means, wherein applicator membersare located upstream from said winding means and downstream from saidinterruption zone for application of a moistening product to said webmaterial to provide rolls of soaked or moistened web material. 13.Winding machine according to claim 12, wherein said winding meanscomprise a winding cradle with peripheral winding members in contactwith the forming roll.
 14. Winding machine according to claim 13,wherein said applicator members are located at one of said peripheralwinding members along which said web material is passed in order toapply said moistening product to the web material which is in contactwith said winding member.
 15. Winding machine according to claim 13,wherein said applicator members comprise a set of spray nozzles. 16.Winding machine according to claim 13 or 15, further comprising a devicefor interrupting the web material upstream from said winding means alongsaid feed path and in which the applicator members are located along thefeed path between the winding means and the device for interrupting theweb material, wherein said device for interrupting the web materialcomprises a blade which acts together with a counterblade in a rolleraround which said web material is fed, wherein said roller equipped withsaid counterblade is one of said peripheral winding members.
 17. Windingmachine according to claim 15, further comprising a rolling plate alongthe feed path upstream of the winding cradle along which an initial coreof the forming roll is caused to roll, said rolling plate terminating ina vicinity of the winding cradle, and in that said applicator membersare associated with the terminal end of the rolling plate located in thevicinity of the winding cradle.
 18. Winding machine according to claim17, wherein: said winding members comprise at least one winding rollerequipped with a plurality of annular grooves, said rolling plate has aplurality of teeth extending into said annular grooves in the windingroller, and in that the applicator members comprise nozzles constructedin correspondence of said teeth of the rolling plate.
 19. Windingmachine according to claim 18, wherein said nozzles open out on saidteeth.
 20. Winding machine according to claim 19, wherein each tooth hastwo divergent nozzles.
 21. Winding machine according to claim 18,wherein said nozzles are located in bases of said teeth.
 22. Windingmachine according to claim 21, wherein said nozzles are in communicationwith a feed duct constructed within said rolling plate.
 23. Windingmachine according to claim 12, wherein said applicator members comprisea set of spray nozzles.
 24. Winding machine according to claim 12, 13,23 or 15, further comprising a device for interrupting the web materialupstream from said winding means along said feed path and in which theapplicator members are located along the feed path between the windingmeans and the device for interrupting the web material.
 25. Windingmachine according to claim 24, wherein said device for interrupting theweb material comprises a blade which acts together with a counterbladein a roller around which said web material is fed.
 26. Winding machineaccording to claim 23, further comprising a rolling plate along the feedpath upstream of a winding cradle along which an initial core of theforming roll is caused to roll, said rolling plate terminating in avicinity of the winding cradle, and in that said applicator members areassociated with the terminal end of the rolling plate located in thevicinity of the winding cradle.
 27. Winding machine according to claim26 or 17, wherein said spray nozzles are constructed in the rollingplate.
 28. Winding machine according to claim 26, wherein: said windingmembers comprise at least one winding roller equipped with a pluralityof annular grooves, said rolling plate has a plurality of teethextending into said annular grooves in the winding roller, and in thatthe applicator members comprise nozzles constructed in correspondence ofsaid teeth of the rolling plate.
 29. Winding machine according to claim28, wherein said nozzles open out on said teeth.
 30. Winding machineaccording to claim 29, wherein each tooth has two divergent nozzles. 31.Winding machine according to claim 28, wherein said nozzles are locatedin bases of said teeth.
 32. Winding machine according to claim 31,wherein said nozzles are in communication with a feed duct constructedwithin said rolling plate.
 33. Winding machine according to claim 26,32, 17 or 25, wherein said rolling plate oscillates and acts togetherwith a feed roller for the web material to cause interruption of the webmaterial by pinching the web material against the feed roller at a pointupstream from the applicator members in the feed direction of the webmaterial.
 34. Winding machine according to claim 12, 13, 23 or 28,wherein a changeover zone in which a leading end of the web materialbegins the formation of a roll is located along said feed path for theweb material, and in that said applicator members are located downstreamfrom said changeover zone in the feed direction for the web materialalong said track.
 35. Winding machine according to claims 23 or 15,wherein said spray nozzles are in a rolling plate along the feed pathupstream of a winding cradle.